PPAP's WorldWide – PPAP's WorldWide

PPAP Services

A valuable tool for establishing confidence in component suppliers and their production processes.

Create, review, & verify PPAP submissions
First article inspection (FAI)
Conduct source inspections, witness run@rates, & process audits
Annual validations or revalidations of PPAPs
IMDS approvals
Product compliance REACH, RoHS, & conflict minerals
24/7 Technical Support

Supplier PPAPs

Raise Request and follow up with suppliers for PPAP submissions and re-submissions. Review, Verify all PPAP requirements & Approve the complete PPAP packageEscalation and follow up action items.

Customer PPAPs

Help create balloon drawings, dimensional Report from CMM, etc. Help create and verify, PFD, PFMEA, Control plans, Work Instructions, etc.Conduct CpK, SPC studies and MSA studies Conduct run@ rate studies Gather PPAP documents. Review, Verify and internally approve PPAP package to send to end customer for approval. Approve supplier PPAPs before sending customer PPAPs.

Annual PPAPs / Revalidation of PPAPs

Work with customer’s Manufacturing plants for Annual PPAP approvals

Our PPAP experiences include the following:

Electrical
Electronics
Mechatronics
Sheet metal
Stampings
Injection molded Plastics
Die casting

Machining
Forging
Rubber
Composites & Others
Mechanical
Fabrications
Hydraulics & others

The Production Part Approval Process ( PPAP ) is a process of product design and manufacturing standardization within the automotive and aerospace industries.

PPAP defines generic requirements for production part approval, including production & bulk materials. The purpose of PPAP is to determine if all customer engineering design record & specifications are properly understood by the organization and that the manufacturing process has the potential to produce product consistently meeting these requirements during an actual production run at the quoted production rate.

Review the process

Identify the process and the comprised steps through a detailed diagram. Identify what each step is intended to accomplish.

Assign a severity ranking

Assign a severity ranking 1 ( low ) – 10 (dangerous) to each of the identified PF as a consequence of it actually occurring.

Potential causes of failure

Identity the process elements that could trigger potential failures.

Calculate the RPN (risk priority number)

S x O x D=RPN 1 (low) – 1000 (high risk). Make a determination if the calculated number is acceptable for the failure being analyzed.

Assign an occurrence ranking

Assign an occurrence ranking from 1 (least) – 10 (extremely likely) to each failure based on the likelihood it will fail.

Assign a detection ranking

Assign detection rankings based easiness of detection before failure happens. (1 easy – 10 extremely difficult to detect)

Develop an action plan

Detail process controls and detection methods to decrease the RPN and implement them into the process.

Potential failure mode(s)

Identify potential failure(s) for each step of the process (potential failure mode).

Potential effects of failure(s)

If the identified failure(s) were to occur list the impact it would have on production capacity, the next sequential step, or the finished product.

Recalculate the RPN

Once failure control methods are in place, recalculate the RPN to measure any improvements.

How PPAP Automation adds value ? Click below to watch short video...

Product and Plant Compliance Services

1. IMDS

2. REACH

3. ROHS

4. Conflict Minerals

5. PROP 65

6. WEEE – Waste Electrical and electronics Equipment

7. ELV - End of Life Vehicle

8. Product Compliance

EHS

- Master / Regulatory Compliance Management

- Create – Allocate – Review – Approve

- Incident / Near Miss Recording

- Location & Plant based Scoring and Compliance Dashboards

- Policy Portal, Supplier Compliance

- Emission Recording & Reporting

- Audit Management leading to CAPA

We are full service and Solutions Company with specialized expertise on following:

Engineering

Product Development ( Concept to Prototype)
CAD/FEA/CAM Services
Technical Documentation (Assembly Animation)
Reverse Engineering
Benchmarking
Should Costing
Value Engineering & Value Analysis ( VA/VE)

Workforce & Staffing Management

Contract Staffing & Staff Augmentation
Direct Hiring
Recruitment Process Outsourcing
VMS / MSP

Quality Services

Supplier Quality Engineer
Audits & Inspections
Root Cause Analysis
3rd Party Audits
Supplier Development
Training

Technology Solutions

Quality Life Cycle Management

WaveOne

UpGlide

APQP / Program Management
PPAP Workflow & Automation
Supplier Portal
Non Conformity Management ( NC)- CAPA, 8D
Audit Management
KPI’s, Dashboards, COPQ
Compliance/EHS Management System

Workflow
BOM Management
Product Structures
ECR/ECN
Traceability
Document Management System- Release and Version Control

Vendor Management System
Staffing Lifecycle Management
Contingent Workforce Management
Req. to Chq
Timesheet Management System

Frequently Asked Questions

What are the benefits of PPAP ?

Helps to validate quality processes and design conformity. Identifies problem(RISKs) early for resolution through PFMEA Process. Reduces cost of poor quality (COPQ) through quality process control.Provides guidance for managing supplier and manufacturer changes. Prevents use of unauthorized and malfunctioning parts. Identify Potential Supplier with strong process Knowledge. Identifies supplier areas for improvement. Improves the overall quality of products & customer satisfaction.

How did PPAP come to inception ?

In 1982, the management staff of GM, FCA, and Ford founded Automotive Industry Action Group (AIAG). The group then developed Advanced Product Quality Planning (APQP) & Control Plan specifications. Within these standards, AIAG developed PPAP to advance the parts production approval process of quality planning.The first manual to formally document the multiple PPAP requirements was published in 1993. PPAP is a part of the automotive industry’s overall APQP initiative. The goal of PPAP is to provide step-by-step procedures of Manufacturing Process to ensure the production of an end product will satisfy customers. Today, PPAP is being adopted by all industries.

Who regulates PPAP ?

For the automotive industry, AIAG currently governs PPAP to ensure all parties conform to the same set of standards.

When is a PPAP required ?

A PPAP is required anytime a new part or change to an existing part/ process is being planned. This includes:</p> <p>Correction of a non-conformity on a previously submitted part Use of alternative material that was used in the previously approved part Production from new or modified tooling, including additional or replacement tooling Production following refurbishment or rearrangement of existing tooling or equipment Production following any change in process or method of manufacture Production from tooling and equipment transferred to or from a different plant location Change of source for sub tiers parts, material or services (e.g., heat treatment, plating) Product that was not produced in the last 12 months or more Change in test or inspection method & for additional capacity (additional production line/Location).

What's included in a PPAP ?

The PPAP manual is the ultimate resource for those in automotive supplier quality management. The manual contains the PPAP checklist, which includes all the requirements, called elements, for a complete PPAP package. The checklists identifies different PPAP levels (from 1 to 5). For those in the automotive industry, there are 18 possible elements that must be checked off. The aerospace industry has a similar set of elements to be completed during the development, planning, and design of the production process. Each PPAP level determines the specific requirements for each element and indicates which elements should be submitted to the customer. It is important to note regardless of PPAP level, the supplier must complete every applicable element with respect to PPAP submission levels.

What are PPAP submission levels ?

Customers specify how detailed they want suppliers to be with PPAPs through submission level requirements. Any combination of the following requirements comprises each level: PSW, part samples, limited supporting data, complete supporting data, customer proposed requirements, and review at manufacturing location. Levels clarify customer requirements to suppliers the amount of evidence that should be included in their submissions.Level 1: Part submission warrant (PSW) only (and for designated appearance items, an AAR) submitted to the customer Level 2: PSW with part samples and limited supporting data Level 3: PSW with part samples and complete supporting data Level 4: PSW and other requirements proposed by the customer Level 5: PSW with part samples and complete supporting data available for review at the supplier’s manufacturing location.

Why is PPAP negotiation necessary ?

PPAP is similar to a strategic project plan; it is the direct negotiation between a customer and supplier that confirms how each PPAP element is satisfied. Not every PPAP is the same; therefore, negotiation must take place prior to accepting the requirements and initiating the process. This ensures that both parties have the same expectations. In many cases, the supplier will have an established report/document like a control plan, FMEA, SPC, MSA etc. that will help guide the customer through its process. If the already established report/document by the supplier is found acceptable by the customer, the same documents may be duplicated and reused by the supplier in the future.

What are the required PPAP elements ?

1.Design Record: Copy of drawings(each feature and notes are ballooned),technical specifications/standards 2.Engineering Change Documents, if any: outlines any changes to the design and are usually included within engineering change documents. 3.Customer Engineering Approval, if required: Contingent on requirement. The approval comes from Sample/Proto part production trial in the customer’s manufacturing plant. 4.Design Failure Mode and Effects Analysis (DFMEA): Looks at the probability of part failure from design and its effect on the intended function of the product.5.Process flow diagrams: Graphical outline of the steps & sequence of the manufacturing process for a part from start to finish to meet the customer needs, requirements & expectations.6.Process Failure Mode and Effects Analysis (PFMEA): It is a disciplined review and analysis of a new or revised process and is conducted to anticipate, resolve, or monitor potential process problems for a new or revised product program. 7.Control plan: The control plan is a written description of the systems for controlling production parts and processes. The production control plan is a living document and should be updated to reflect the addition/deletion of controls based on experience gained by producing parts (Approval of authorized customer representative may be required) 8.Measurement System Analysis (MSA) Studies: It is the statistical method used to know the variation in the measurement system, which includes Gauge R&R, Linearity, Stability, Bias, Kappa, etc. 9.Dimensional Results: shows physical part measurements meets drawing requirement. 10.Material, Performance Test Results: A summary of all the tests performed on the part as specified in the drawing. 11.Initial process studies: includes all SPC charts to prove processes producing critical/significant characteristics have stable variability.

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